Diesel engines 1.7 and 1.9 l car Volkswagen Polo 3
Diesel engines AKW, ANV 1.7 SDI, AEY 1.9 SDI, AFN, AHU and ALE 1.9 TDI, 1Y 1.9 D
Engine code The engine code is stamped between the injection pump and the vacuum pump on the cylinder block (pic. 6.1). Additionally, the engine code is also affixed to the timing...
Engine code The engine code is stamped between the injection pump and the vacuum pump on the cylinder block (pic. 6.1). Additionally, the engine code is also affixed to the timing...
Engine disassembly
Engine elements are shown in fig. 6.2 a-c. Pic. 6.2 a. Engine elements: 1, 9, 11, 13, 22 - Bolts; 2 - Washer; 3, 8, 32 - Tension rollers; 4 - Tension lever; 5 - Retainer; 6 -...
Engine elements are shown in fig. 6.2 a-c. Pic. 6.2 a. Engine elements: 1, 9, 11, 13, 22 - Bolts; 2 - Washer; 3, 8, 32 - Tension rollers; 4 - Tension lever; 5 - Retainer; 6 -...
Timing belt drive with single pulley injection pump
Removing 1. Remove the ribbed belt. 2. Remove the ribbed belt tensioner, if installed. 3. Remove the upper part of the timing case and the cylinder head cover. 4. Align the TDC...
Removing 1. Remove the ribbed belt. 2. Remove the ribbed belt tensioner, if installed. 3. Remove the upper part of the timing case and the cylinder head cover. 4. Align the TDC...
Timing belt drive with double pulley injection pump
Engine 1Y Removing 1. Remove the ribbed belt. 2. If installed, remove the ribbed belt tensioner. 3. Remove the upper part of the timing case and the cylinder head cover. 4. Align...
Engine 1Y Removing 1. Remove the ribbed belt. 2. If installed, remove the ribbed belt tensioner. 3. Remove the upper part of the timing case and the cylinder head cover. 4. Align...
Sealing flange and flywheel / drive plate / pressure plate
Sealing flange and flywheel/drive plate/pressure plate are shown in fig. 6.12. Pic. 6.12. Sealing flange and flywheel / drive plate / pressure plate: 1, 14 - Oil seals; 2 - Key;...
Sealing flange and flywheel/drive plate/pressure plate are shown in fig. 6.12. Pic. 6.12. Sealing flange and flywheel / drive plate / pressure plate: 1, 14 - Oil seals; 2 - Key;...
Crankshaft
The crankshaft is shown in fig. 6.13. Pic. 6.13. Crankshaft: 1 - Inserts 1, 2, 4 and 5 bearings; 2, 7 - Bolts; 3 - Indigenous covers; 4 - Insert 3 bearings; 5, 10 - Thrust half...
The crankshaft is shown in fig. 6.13. Pic. 6.13. Crankshaft: 1 - Inserts 1, 2, 4 and 5 bearings; 2, 7 - Bolts; 3 - Indigenous covers; 4 - Insert 3 bearings; 5, 10 - Thrust half...
Connecting rod and piston group
The piston and connecting rod are shown in fig. 6.14. Pic. 6.14. Piston and connecting rod: 1 - Piston rings; 2 - Piston; 3 - Piston pin; 4 - Retaining ring; 5 - Connecting rod; 6...
The piston and connecting rod are shown in fig. 6.14. Pic. 6.14. Piston and connecting rod: 1 - Piston rings; 2 - Piston; 3 - Piston pin; 4 - Retaining ring; 5 - Connecting rod; 6...
Checking piston protrusion at TDC
Piston protrusion at TDC is made when installing a new piston (pic. 6.17). Depending on the protrusion of the piston, the cylinder head gasket is installed (tables 6.3 a, b). Head...
Piston protrusion at TDC is made when installing a new piston (pic. 6.17). Depending on the protrusion of the piston, the cylinder head gasket is installed (tables 6.3 a, b). Head...
Cylinder head
The cylinder head is shown in fig. 6.19. Pic. 6.19. Cylinder head: 1, 4, 6, 19, 29, 31 - Bolts; 2 - Upper part of the timing belt guard; 3 - Toothed timing belt; 5 - Camshaft...
The cylinder head is shown in fig. 6.19. Pic. 6.19. Cylinder head: 1, 4, 6, 19, 29, 31 - Bolts; 2 - Upper part of the timing belt guard; 3 - Toothed timing belt; 5 - Camshaft...
Compression test
4.1. Engines AEY, AFN, ANV, AHU, AKW, ALE 1. Disconnect the wiring connector from the shut-off valve on the injection pump. 2. Disconnect the wiring connector from the injection...
4.1. Engines AEY, AFN, ANV, AHU, AKW, ALE 1. Disconnect the wiring connector from the shut-off valve on the injection pump. 2. Disconnect the wiring connector from the injection...
Gas distribution mechanism
Elements of the gas distribution mechanism are shown in fig. 6.25. Pic. 6.25. Elements of the gas distribution mechanism: 1 - Root covers of the camshaft; 2 - Nut; 3 - Camshaft; 4...
Elements of the gas distribution mechanism are shown in fig. 6.25. Pic. 6.25. Elements of the gas distribution mechanism: 1 - Root covers of the camshaft; 2 - Nut; 3 - Camshaft; 4...
Valve seat processing
1. Insert the valve and press it firmly against the seat. 2. Measure the distance between the end of the valve stem and the top edge of the cylinder head (pic. 6.29). 3. Calculate...
1. Insert the valve and press it firmly against the seat. 2. Measure the distance between the end of the valve stem and the top edge of the cylinder head (pic. 6.29). 3. Calculate...
Checking the valve guide
1. Insert the new valve into the sleeve so that the end of its stem is flush with the edge of the valve sleeve. 2. Determine the gap between the sleeve and the valve (pic. 6.33)....
1. Insert the new valve into the sleeve so that the end of its stem is flush with the edge of the valve sleeve. 2. Determine the gap between the sleeve and the valve (pic. 6.33)....
Checking hydraulic lifters
Attention! A defective hydraulic compensator must be replaced as a whole. It is beyond repair. Irregular clanging noise when starting the engine is normal. 1. Start the engine and...
Attention! A defective hydraulic compensator must be replaced as a whole. It is beyond repair. Irregular clanging noise when starting the engine is normal. 1. Start the engine and...
Replacement of the vortex chamber (only on 1Y engines)
Measure the protrusion of the vortex chamber (pic. 6.35). Specification value: 0.07 mm. If the required value is not achieved, replace the cylinder head.
Measure the protrusion of the vortex chamber (pic. 6.35). Specification value: 0.07 mm. If the required value is not achieved, replace the cylinder head.
Lubrication system
The elements of the lubrication system are shown in fig. 6.36. Pic. 6.36. Elements of the lubrication system: 1 - Cover: 2, 12, 23 - Gaskets; 3 - Oil level indicator; 4 - Guide...
The elements of the lubrication system are shown in fig. 6.36. Pic. 6.36. Elements of the lubrication system: 1 - Cover: 2, 12, 23 - Gaskets; 3 - Oil level indicator; 4 - Guide...
Checking oil pressure and pressure sensor
1. Unscrew the pressure sensor (0.25 bar, blue) and screw it into the tester (pic. 6.39). 2. Screw the tester adapter into the hole for the pressure sensor in the cylinder head....
1. Unscrew the pressure sensor (0.25 bar, blue) and screw it into the tester (pic. 6.39). 2. Screw the tester adapter into the hole for the pressure sensor in the cylinder head....
Cooling system
Elements of the cooling system are shown in fig. 6.40, 6.41. The cooling system pump is shown in fig. 6.42. Pic. 6.40. Elements of the cooling system: 1 - Clamp; 2 - Bolts with...
Elements of the cooling system are shown in fig. 6.40, 6.41. The cooling system pump is shown in fig. 6.42. Pic. 6.40. Elements of the cooling system: 1 - Clamp; 2 - Bolts with...
Supply system
Elements of the power supply system Polo Classic, Polo Estate are shown in fig. 6.43, elements of the Caddy power system - in fig. 6.44. Pic. 6.43. Elements of the power supply...
Elements of the power supply system Polo Classic, Polo Estate are shown in fig. 6.43, elements of the Caddy power system - in fig. 6.44. Pic. 6.43. Elements of the power supply...
Fuel filter
The fuel filter is shown in fig. 6.47. Pic. 6.47. Fuel filter: 1 - Drain fuel line from injection pump; 2 - Intake fuel line to high pressure fuel pump; 3 - O-ring; 4 - Control...
The fuel filter is shown in fig. 6.47. Pic. 6.47. Fuel filter: 1 - Drain fuel line from injection pump; 2 - Intake fuel line to high pressure fuel pump; 3 - O-ring; 4 - Control...
Accelerator pedal
The accelerator pedal of cars with the 1Y engine is shown in fig. 6.48 a, cars with engines AEY, ANV, AHU, AKW, ALE - in fig. 6.48 b, cars with an AFN engine - in fig. 6.48 in....
The accelerator pedal of cars with the 1Y engine is shown in fig. 6.48 a, cars with engines AEY, ANV, AHU, AKW, ALE - in fig. 6.48 b, cars with an AFN engine - in fig. 6.48 in....
Checking the Accelerator Pedal Position Sensor (engines AEY, AFN, ANV, AHU, AKW, ALE)
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial «01» «Engine electronics». The engine must be running at idle. The display should show the following information:...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial «01» «Engine electronics». The engine must be running at idle. The display should show the following information:...
Accelerator pedal position sensor adjustment (engines AEY, AFN, ANV, AHU, AKW, ALE)
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial «01» «Engine electronics». The engine must be running at idle. The display should show the following information:...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial «01» «Engine electronics». The engine must be running at idle. The display should show the following information:...
Turbocharged diesel engine
The turbocharger with attached elements of AHU, ALE engines is shown in fig. 6.58 a, AFN engine - in fig. 6.58 b. Pic. 6.58 a. Turbocharger with attached engine elements AHU, ALE:...
The turbocharger with attached elements of AHU, ALE engines is shown in fig. 6.58 a, AFN engine - in fig. 6.58 b. Pic. 6.58 a. Turbocharger with attached engine elements AHU, ALE:...
Intercooler (intercooling of charge air)
Intercooler elements (aftercooling of charge air) shown in fig. 6.59. Pic. 6.59. Intercooler elements (aftercooling of charge air): 1 - Exhaust manifold; 2 - Connecting tube...
Intercooler elements (aftercooling of charge air) shown in fig. 6.59. Pic. 6.59. Intercooler elements (aftercooling of charge air): 1 - Exhaust manifold; 2 - Connecting tube...
Exhaust gas recirculation system
The location of the tubes of the exhaust gas recirculation system of AHU, ALE engines is shown in fig. 6.60 a, AFN engine - in fig. 6.60 b. Location of elements of the exhaust gas...
The location of the tubes of the exhaust gas recirculation system of AHU, ALE engines is shown in fig. 6.60 a, AFN engine - in fig. 6.60 b. Location of elements of the exhaust gas...
Checking the elements of the exhaust gas recirculation system
On 1Y engine 1. Start the engine and let it idle. 2. The EGR valve diaphragm should move towards the tube fitting (can be identified by touch below the arrow) (pic. 6.62). Exhaust...
On 1Y engine 1. Start the engine and let it idle. 2. The EGR valve diaphragm should move towards the tube fitting (can be identified by touch below the arrow) (pic. 6.62). Exhaust...
Checking the mechanical EGR valve
AHU engine 1. Disconnect the vacuum tube from the EGR valve. 2. Connect the hand pump VAG 1390 to the valve. 3. Pump (pic. 6.66). The diaphragm rod must move to the vacuum...
AHU engine 1. Disconnect the vacuum tube from the EGR valve. 2. Connect the hand pump VAG 1390 to the valve. 3. Pump (pic. 6.66). The diaphragm rod must move to the vacuum...
Diesel injection control system
The location of the elements of the diesel fuel injection system in the engine compartment of vehicles with AEY, ANV, AKW engines is shown in fig. 6.68 a, cars with AFN, AHU, ALE...
The location of the elements of the diesel fuel injection system in the engine compartment of vehicles with AEY, ANV, AKW engines is shown in fig. 6.68 a, cars with AFN, AHU, ALE...
Self-diagnosis of the injection system
The fuel injection system control unit is equipped with a fault memory that records sensor or system faults, indicating the type of fault. Sometimes there are malfunctions that...
The fuel injection system control unit is equipped with a fault memory that records sensor or system faults, indicating the type of fault. Sometimes there are malfunctions that...
Connecting a fault code reader VAG 1551
1. Open the lid of the glove box on the driver's side and connect the VAG 1551 fault code reader using the VAG 1551/3 wire (pic. 6.70). 2. After connecting the DTC reader,...
1. Open the lid of the glove box on the driver's side and connect the VAG 1551 fault code reader using the VAG 1551/3 wire (pic. 6.70). 2. After connecting the DTC reader,...
Fault memory interrogation
To interrogate the fault memory, a VAG 1551 fault code reader and a VAG 1551/3 wire are required. 1. Connect the VAG 1551 fault code reader (V.A.G 1552) and by typing «01»...
To interrogate the fault memory, a VAG 1551 fault code reader and a VAG 1551/3 wire are required. 1. Connect the VAG 1551 fault code reader (V.A.G 1552) and by typing «01»...
Clearing the fault memory
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and by typing «01» «Engine electronics», select the engine control unit. The engine must be running at idle. The display...
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and by typing «01» «Engine electronics», select the engine control unit. The engine must be running at idle. The display...
Reading a block of measured values
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial «01» «Engine electronics» The engine must be running at idle. The display should show the following information: 2....
1. Connect the VAG 1551 fault code reader (V.A.G 1552) and dial «01» «Engine electronics» The engine must be running at idle. The display should show the following information: 2....
Removal and installation of injection pump
Removing 1. Remove the air filter. 2. Remove the top part of the timing belt cover. 3. Remove the cylinder head cover. 4. Align the TDC marks on the piston of cylinder No. 1 on...
Removing 1. Remove the air filter. 2. Remove the top part of the timing belt cover. 3. Remove the cylinder head cover. 4. Align the TDC marks on the piston of cylinder No. 1 on...
Checking the valve timing
1. Remove the top part of the timing belt cover. 2. Remove the cylinder head cover. 3. Align the TDC marks on the piston of cylinder No. 1 on the crankshaft: A - Engines AEY, ANV,...
1. Remove the top part of the timing belt cover. 2. Remove the cylinder head cover. 3. Align the TDC marks on the piston of cylinder No. 1 on the crankshaft: A - Engines AEY, ANV,...
Checking the injectors
Injectors are tested on the stand (pic. 6.75). At the moment of spraying the fuel, check the opening pressure. Engines AEY, AFN, ANV, AHU, AKW Specification value: new nozzle -...
Injectors are tested on the stand (pic. 6.75). At the moment of spraying the fuel, check the opening pressure. Engines AEY, AFN, ANV, AHU, AKW Specification value: new nozzle -...
Checking the crankshaft speed sensor
1. Turn off the ignition. 2. Disconnect the wiring connector from the crankshaft speed sensor. 3. Measure the resistance between pins 1 and 2 of the connector (pic. 6.76)....
1. Turn off the ignition. 2. Disconnect the wiring connector from the crankshaft speed sensor. 3. Measure the resistance between pins 1 and 2 of the connector (pic. 6.76)....
Checking the coolant temperature sensor
1. Connect tester VAG 1551 and dial «01» to select a function «Address word» engine control unit. The engine must be running at idle. The display should show the following...
1. Connect tester VAG 1551 and dial «01» to select a function «Address word» engine control unit. The engine must be running at idle. The display should show the following...
Checking the temperature sensor in the intake manifold (on engines AFN, AHU, ALE)
1. Connect tester VAG 1551 and dial «01» to select a function «Address word» engine control unit. The engine must be running at idle. The display should show the following...
1. Connect tester VAG 1551 and dial «01» to select a function «Address word» engine control unit. The engine must be running at idle. The display should show the following...
Checking the intake air temperature sensor (on engines AEY, ANV, AKW)
Connect tester VAG 1551 and dial «01» to select a function «Address word» engine control unit. The engine must be running at idle. The display should show the following...
Connect tester VAG 1551 and dial «01» to select a function «Address word» engine control unit. The engine must be running at idle. The display should show the following...
Checking the fuel temperature sensor
1. Connect the VAG 1551 tester and by typing «01» «Engine electronics», select the engine control unit. The engine must be running at idle. The display should show the following...
1. Connect the VAG 1551 tester and by typing «01» «Engine electronics», select the engine control unit. The engine must be running at idle. The display should show the following...
Checking the nozzle needle displacement sensor
1. Turn off the ignition. 2. Disconnect the wiring connector from the injector needle movement sensor. 3. Measure the resistance between the pins of the connector (pic. 6.92). Set...
1. Turn off the ignition. 2. Disconnect the wiring connector from the injector needle movement sensor. 3. Measure the resistance between the pins of the connector (pic. 6.92). Set...
Fault codes
Fault code Failed node 00282 Throttle position sensor 00513 crankshaft speed sensor 00519 Intake manifold pressure sensor 00522 coolant temperature sensor 00523 Inlet air...
Fault code Failed node 00282 Throttle position sensor 00513 crankshaft speed sensor 00519 Intake manifold pressure sensor 00522 coolant temperature sensor 00523 Inlet air...
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Polo 4
Polo 3
- General information
- User manual
- Maintenance
- Power unit
- Engine repair
- Cooling and lubrication system
- Control system
- Injection system (diesel)
- Supply system
- Exhaust system
- Chassis
- Front suspension
- Rear suspension
- Steering
- Wheels and tires
- Brake system
- Body
- Interior
- Exterior
- Electrical equipment
- Equipment and devices
- Wiper system
- Lighting system
- Electrical circuits
- General information
- User manual
- Maintenance
- Power unit
- Petrol engines 1.4 and 1.6
- Petrol engines 1.4 (V16)
- Petrol engines 1.6 and 1.8
- Diesel engines 1.7 and 1.9
- Diesel engines 1.9 D and TD
- Transmission
- Mechanical gearbox 085
- Mechanical gearbox 020/02K
- Chassis
- Front suspension
- Rear suspension
- Steering
- Brake system
- Body
- Exterior
- Interior
- Electrical equipment
- Equipment and instruments (until 2000)
- Equipment and instruments (after 2000)
- Electrical circuits
- Wiring diagrams (petrol)
- Wiring diagrams (diesel)
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